Method of forming a composite pile

ABSTRACT

This invention relates to a method of forming composite piles by pouring in place the bottom portion of the pile in a casing, thence installing an extension of fixed length on top of the bottom portion, and then withdrawing the casing.

United States Patent Cavin 51 Apr. 11,1972

54] METHOD OF FORMING A COMPOSITE 2,636,355 4/1953 Thornley ..6l/53.66 x PILE 2,430,879 11/1947 Kohn ..6l/53.66

[72} Inventor: Lewis Fred Cavin, San Lorenzo, Calif. FOREIGN PATENTS OR APPLICATIONS [73] Assignee: Raymond International, Inc., New York, 605,962 1948 Great Britain ...6l/53.6 N.Y. 521,681 1940 Great Britain ..61/53.6

[22] Filed: May 1970 Primary Examiner-Jacob Shapiro [21] APPL 5 93 Attorney-Lawrence F Scinto, Carroll 0. Harper, Charles W. Bradley. Edwin T. Grimes. William .I. Brunet. Joseph M. Fitzpatrick. John Thomas (fella, Carles B. Cannon and [52] U.S. Cl ..61/53.64, 6l/35, 61/56 Robert 1 Baechwld [51 Int. Cl. ..E02d 5/34, E02d 5/50 [58] Field ofSearch ..6l/53.64,53.66,53.5,53.52, [57] ABSTRACT ThlS invention relates to a method of forming composite piles by pouring in place the bottom portion of the pile in a casing, [56] References Cited thence installing an extension of fixed length on top of the bot- UNTTED STATES PATENTS tom portion, and then withdrawing the casing.

1,775,217 9/1930 Thornley ..6l/53.6 9 Claims, 17 Drawing Figures PATENTEDAPR 11 m2 3,654,767

$HEET 1 UF 4 INVENTOK Lew/s Fee- Cqy/ry PATENTEDAPR 11 I972 3,854, 767

sum 2 OF 4 INVENTOR Laws F860 N "Y 8 WWW METHOD OF FORMING A COMPOSITE PILE This invention relates to a method of forming a pile, and more particularly to a new and improved method of forming a composite load bearing pile.

Heretofore, difficulties were encountered in the trucking and handling of long, heavy, pre-cast piles. Frequently, such piles had to be cut off at the cap elevation after insertion in the hole. In addition, a reinforcing cage was required in the drilled hole, and also the forming of cast-in-place extensions required more reinforcing steel. Moreover, a long waiting period often resulted at the start of the job while piles were being drilled and extensions made. Related patents in this art include U.S. Pat. No. 1,120,974 issued Dec. 15, 1914 and U.S. Pat. No. 1,558,127 issued Oct.20, 1925.

Applicant has discovered a novel method which affords a very economical, efi'rcient and practical solution of the difficulties encountered with the prior art, as will become apparent as the description proceeds. Briefly, in one form of my invention, I provide a method of forming a composite pile by first predrilling a hole in the ground and then driving a tubular casing to a preselected tip depth in the hole. The next steps comprise pouring concrete up to the desired level of the lower end of an extension of preselected length, setting the extension in place, and thence removing the casing from the hole.

There has thus been outlined rather broadly the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described more fully hereinafter. Those skilled in the art will appreciate that the conception on which this disclosure is based may readily be utilized as the basis for the designing of other structures for carrying out the several purposes of the invention. It is important, therefore, that this disclosure be regarded as including such equivalent constructions as do not depart from the spirit and scope of the inventron.

Several embodiments of the invention have been chosen for purposes of illustration and description, and are shown in the accompanying drawings, forming a part of the specification, wherein:

FIGS. lA-lJ are side elevational views, partially in section, representing in a sequential manner, the steps for installing a composite pile according to the present invention;

FIG. 2 is an enlarged longitudinal sectional view of a pair of easing members constructed in accordance with the present invention and used in the sequence of operative steps of FIGS. lA-lJ;

FIG. 3 is a perspective view of the casings of FIG. 2;

FIG. 4 is a reduced perspective view of a plurality of piles supported in vertical orientation by stay lathing in accordance with the invention;

FIG. 5 is a plan view of the construction of FIG. 4;

FIG. 6 is an end view of the construction of FIG. 4;

FIG. 7 is an enlarged, longitudinal, sectional view of a pair of easing members constructed in accordance with another embodiment of the invention; and

FIG. 8 is an enlarged, longitudinal, sectional view of a pair of easing members constructed in accordance with still another embodiment of the invention.

FIGS. lA-lJ show the sequence of steps for installing a composite pile in accordance with the present invention. As il lustrated, the pile is installed within a mass of earth 10, and supported by a firm base 12 of relatively solid earth or rock stratum, thereby providing a proper bearing support for the pile. The depth of the bearing stratum or tip elevation, may vary from location to location, as determined by local code or predrilling.

As illustrated in FIG. 1A, a working hole 14 is predrilled in the earth to within approximately one or two feet of the bearing stratum, as by conventional means such as a hydraulic drill with air applied through the stem, for example.

Referring next to FIG. 18, a tubular open ended casing or shell, indicated generally at 16, includes upper and lower casing sections 18 and 20, respectively. As best seen in FIGS. 2 and 3, the lower section 20 is provided with an annular collar 22 disposed a short distance downwardly of the top end thereof. The lower section has a slightly smaller diameter than the upper section 18 so that the lower section fits telescopically into the upper casing. The upper casing has a cover 23 and a plurality of spaced hooks 24 which are arranged to engage the collar 22 for locking the two casings together. An 0 ring 26, FIG. 2, is disposed between the two casing sections for sealing purposes. Reverting to FIG. 1B, the casing is set and driven to the depth of the tip elevation or bearing stratum 12. The casing may be open ended or a disposable bottom plate, not shown, may be placed over the end to keep out mud and soil during driving. If the casing is driven open ended, a quantity of mud and soil 28 normally enters the bottom thereof. According to the next step, as seen in FIG. 1C, the upper casing section is removed from the lower casing and the soil 28 is removed by means of an auger assembly, indicated generally at 30. The auger assembly comprises a stem portion 32 extending from a support member 34 and carrying a set of helical flights 36 which carry rubber wipers (not shown). The stem is provided with an internal channel (not shown) for passing compressed air from an inlet 38 in the supporting means for cleaning the casing interior of soil as the auger is withdrawn.

After the soil has been removed from the lower casing 20, a slug of concrete 40, such as about 5 feet thereof, is placed in the bottom of the casing, FIG. 1D.

Thereafter, as seen in FIG. IF, the lower casing 20 is pulled upwardly a short distance toward the upper surface of the slug of concrete, such as about 3 feet, for example. Then, concrete 42 is poured into the casing up to the desired level of the lower end of a pre-cast extension 44, FIG. IF, forming a lower piling section. Next, the pre-cast extension 44 is lowered into place. This extension is of known length and is pre-cast at a remote convenient location before being transported to the job site by conventional means. Reinforcing rods 45 extend from the lower end of the pre-cast extension and serve to lock the extension to the poured concrete lower piling section 42.

As best seen in FIGS. 16, 2 and 3, the upper casing 18 is lowered down over the extension 44 and hooked to the lower casing by the hooks 24. Air pressure is then applied through the inlet 46 in the upper casing 18 and both casings are pulled up and over the pre-cast extension 44 until the lower end of the lower casing 20 clears the ground a short distance, such as about 4 feet, for example. Four wedges 48, FIG. III, are then placed around the extension and the lower casing 18 is lowered back down on the wedges to hold the extension plumb and in place.

If there is inadequate head room available at the pile site, the next step is to remove the lower casing 20 and drive it into the ground at the site of the next pile (not shown), and thereafter the upper section 18 is disconnected therefrom. Following that step the upper section of the casing is lowered over the precast extension 44, FIG. 11, and is used to push the previously installed pre-cast extension to grade, while simultaneously pushing the wedges tight in order to insure that the extension stays plumb.

If there is adequate head room available at the piling site, then the step of driving the lower easing into the ground at the site of the next pile may be omitted and the lower casing 20 with the upper casing 18 thereover is lowered over the precast extension 44 for driving it to grade as seen in FIG. 11.

Subsequent to the foregoing step, a stay lathing vise, indicated generally at 50, FIGS. 1], 4, 5 and 6, is attached to hold the extension 44 in proper alignment until the concrete has set. Referring in particular to FIGS. 4-6, the stay lathing assembly includes a pair of elongated facing members 52 and 54 mounted on each side of the pre-cast pile extension 44. These members are provided with cut-out portions 56 and 58, respectively, for gripping the piling. Bolting means 60 serve to lock the members together. The assembly also comprises four concrete blocks 62 positioned on the ground in the four corners and cables 64 having turnbuckles 66 serve to connect the blocks to the facing members 52 and 54, respectively, thereby holding a plurality of piles in position and in proper alignment until the concrete has had a chance to set.

In the embodiment of FIG. 7, an open ended pipe 144 of preselected length is employed instead of the pre-cast pile extension 44. This pipe is installed in the same manner as the pile extension 44 described hereinbefore in connection with FIG. ll. However, in place of the reinforcing rods 45, FIG. ll extending from the lower end of the pre-cast extension, the lower portion 146 of the pipe is driven down into the poured concrete lower piling section 42 a preselected distance to lock the two sections together.

In the embodiment of FIG. 8, an open ended shell-pipe of reselected length, indicated generally at 244, is employed instead of the pre-cast pile extension 44. This shell-pipe is installed in substantially the same manner as the pile extension 44 described hereinbefore in connection with FIG. II. The shell-pipe 244 includes a shell portion 246, FIG. 8, and a pipe portion 248 which is driven down into the poured concrete lower piling section 42 a preselected distance to lock the two sections together. A shoulder 250 is provided against which the upper section 18, FIG. lI,'of the casing engages for pushing the shell-pipe into place.

It will thus be seen that the present invention does indeed provide an improved method of forming composite piles which is superior in simplicity, economy and efficiency as compared to prior art such methods.

Although certain particular embodiments of the invention are herein disclosed for purposes of explanation, various modifications thereof, after study of this specification, will be apparent to those skilled in the art to which the invention pertains.

What is claimed and desired to be secured by Letters Patent is:

l. A method of forming a composite pile comprising the steps of predrilling a hole in the ground, driving a tubular casing to the tip depth in said hole, pouring concrete into said casing to fill it up to the desired level of the lower end of a precast extension of fixed length, setting said pre-cast extension in place, and removing said casing from said hole and allowing said concrete to set, said method further including the steps, subsequent to the removing of the casing from the hole, of inserting wedges between the ground and the pre-cast extension, and placing the casing onto the wedges to firmly set them and hold the pre-cast extension in vertical alignment, and thence setting the casing onto the top of the pre-cast extension to push it to final grade and tighten the wedges in place.

2. A method of forming a composite pile according to claim 1 further comprising the step of pouring a slug of concrete into said tubular casing subsequent to the driving of said casing to tip depth in said hole, lifting said casing up until the lower end thereof is near-the upper surface of said slug of concrete, and thence pouring concrete up to the desired level of the lower end of said pre-cast extension of fixed length.

3. A method of forming a composite pile according to claim 1, further comprising the step, subsequent to the setting of the pre-cast extension in place, of lowering an upper casing down over the extension to hook onto the lower portion of the casing, and thence lifting both casings upwardly until the lower end of the lower casing clears the ground.

4. A method of forming a composite pile according to claim 1 further comprising the step, subsequent to the step of driving a tubular casing in the hole, of passing a fluted auger down inside said casing and withdrawing same to clean out said casing.

5. A method of forming a composite pile according to claim l and further including the step, during the removing of said casing from the hole, of maintaining air pressure therein to hold down said extension and said poured concrete.

6. A method of forming a composite pile comprising the steps of predrilling a hole in theground, driving a lower tubular casing to the tip depth in san hole, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said precast extension in place, lowering an upper casing down over said pre-cast extension to connect onto the lower casing, and removing both of said casings from said hole and allowing said concrete to set, said method further comprising the step, subsequent to the step of removing the casings from the hole, of driving a lower portion of the casing into the ground on the site of the next pile, disconnecting the upper half of the casing and using it to push the previously installed pre-cast extension to grade, and leaving the wedges in place between the ground and the pre-cast extension until the concrete hardens.

7. A method of forming a composite pile comprising the steps of predrilling a hole in the ground, driving a tubular casing to the tip depth in said hole, pouring concrete into said casing to fill it up to the desired level of the lower end of a precast extension of fixed length, setting said pre-cast extension in place, and removing said casing from said hole and allowing said concrete to set, said method further comprising the step, subsequent to the step of removing said casing from said hole, of attaching stay lathing to said pre-cast extension and interconnecting it with a plurality of like-formed piles to maintain mutual alignment while allowing said concrete to set.

8. A method of forming a composite pile comprising the steps of predrilling a hole in the ground to within a short distance of tip depth in the ground, driving a lower tubular casing to tip depth in said hole, pouring a slug of concrete into said lower casing, lifting said lower casing until the lower end thereof is near the upper surface of said slug of concrete, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place on top of said poured concrete, lowering an upper casing down over said pre-cast extension to hook onto the lower casing, lifting both casings up until the lower end of the lower casing clears the ground, inserting wedges between the ground and the pre-cast extension, placing the lower casing onto wedges to firmly set them and hold the pre-cast extension vertically, setting the lower casing onto the top of the pre-cast extension to push it to final grade and tighten said wedges in place, and attaching stay lathing to said pre-cast extension while allowing said concrete to set.

9. A method of forming a composite pile comprising the steps of predrilling a hole in the ground to within a short distance of the tip depth in the hole, driving a lower tubular casing to tip depth in said hole, pouring a slug of concrete into said tubular casing, lifting said lower casing until the lower end thereof is near the upper surface of said slug, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place on top of said concrete, lowering an upper casing down over the pre-cast extension to hook onto the lower casing, lifting both casings up until the lower end of the lower casing clears the ground, inserting wedges between the ground and the pre-cast extension, placing the lower casing onto the wedges to firmly set them and hold the pre-cast extension vertical, driving the lower casing into the ground on the site of the next pile, disconnecting the upper half of the casing and using it to push the previously installed pre-cast extension to grade, and attaching stay lathing to said pre-cast extension while allowing said concrete to set. 

1. A method of forming a composite pile comprising the steps of predrilling a hole in the ground, driving a tubular casing to the tip depth in said hole, pouring concrete into said casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place, and removing said casing from said hole and allowing said concrete to set, said method further including the steps, subsequent to the removing of the casing from the hole, of insertinG wedges between the ground and the pre-cast extension, and placing the casing onto the wedges to firmly set them and hold the pre-cast extension in vertical alignment, and thence setting the casing onto the top of the pre-cast extension to push it to final grade and tighten the wedges in place.
 2. A method of forming a composite pile according to claim 1 further comprising the step of pouring a slug of concrete into said tubular casing subsequent to the driving of said casing to tip depth in said hole, lifting said casing up until the lower end thereof is near the upper surface of said slug of concrete, and thence pouring concrete up to the desired level of the lower end of said pre-cast extension of fixed length.
 3. A method of forming a composite pile according to claim 1, further comprising the step, subsequent to the setting of the pre-cast extension in place, of lowering an upper casing down over the extension to hook onto the lower portion of the casing, and thence lifting both casings upwardly until the lower end of the lower casing clears the ground.
 4. A method of forming a composite pile according to claim 1 further comprising the step, subsequent to the step of driving a tubular casing in the hole, of passing a fluted auger down inside said casing and withdrawing same to clean out said casing.
 5. A method of forming a composite pile according to claim 1 and further including the step, during the removing of said casing from the hole, of maintaining air pressure therein to hold down said extension and said poured concrete.
 6. A method of forming a composite pile comprising the steps of predrilling a hole in the ground, driving a lower tubular casing to the tip depth in said hole, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place, lowering an upper casing down over said pre-cast extension to connect onto the lower casing, and removing both of said casings from said hole and allowing said concrete to set, said method further comprising the step, subsequent to the step of removing the casings from the hole, of driving a lower portion of the casing into the ground on the site of the next pile, disconnecting the upper half of the casing and using it to push the previously installed pre-cast extension to grade, and leaving the wedges in place between the ground and the pre-cast extension until the concrete hardens.
 7. A method of forming a composite pile comprising the steps of predrilling a hole in the ground, driving a tubular casing to the tip depth in said hole, pouring concrete into said casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place, and removing said casing from said hole and allowing said concrete to set, said method further comprising the step, subsequent to the step of removing said casing from said hole, of attaching stay lathing to said pre-cast extension and interconnecting it with a plurality of like-formed piles to maintain mutual alignment while allowing said concrete to set.
 8. A method of forming a composite pile comprising the steps of predrilling a hole in the ground to within a short distance of tip depth in the ground, driving a lower tubular casing to tip depth in said hole, pouring a slug of concrete into said lower casing, lifting said lower casing until the lower end thereof is near the upper surface of said slug of concrete, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place on top of said poured concrete, lowering an upper casing down over said pre-cast extension to hook onto the lower casing, lifting both casings up until the lower end of the lower casing clears the ground, inserting wedges between the ground and the pre-cast extension, placing the lower casing onto wedges to firmly set them aNd hold the pre-cast extension vertically, setting the lower casing onto the top of the pre-cast extension to push it to final grade and tighten said wedges in place, and attaching stay lathing to said pre-cast extension while allowing said concrete to set.
 9. A method of forming a composite pile comprising the steps of predrilling a hole in the ground to within a short distance of the tip depth in the hole, driving a lower tubular casing to tip depth in said hole, pouring a slug of concrete into said tubular casing, lifting said lower casing until the lower end thereof is near the upper surface of said slug, pouring concrete into said lower casing to fill it up to the desired level of the lower end of a pre-cast extension of fixed length, setting said pre-cast extension in place on top of said concrete, lowering an upper casing down over the pre-cast extension to hook onto the lower casing, lifting both casings up until the lower end of the lower casing clears the ground, inserting wedges between the ground and the pre-cast extension, placing the lower casing onto the wedges to firmly set them and hold the pre-cast extension vertical, driving the lower casing into the ground on the site of the next pile, disconnecting the upper half of the casing and using it to push the previously installed pre-cast extension to grade, and attaching stay lathing to said pre-cast extension while allowing said concrete to set. 